TOYOTA AVENSIS 2005 Service Repair Manual

D08112
D08113
D08114
SST
SST
D03827
D03826
40±94
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the tapered roll-
er bearing.
(b) Using a piston ring compressor, squeeze the snap ring.
(c) Using SST a press, press in the outer race of the tapered
roller bearing.
SST 09950±60020 (09951±00890), 09950±70010
(09951±07100)
(d) Install the underdrive planetary ring gear to the counter
driven gear.
(e) Using snap ring pliers, install the snap ring.

D03692
D08117
D08118
SSTSST
D03694
D08120
SST
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
40±95
U241E A/T REPAIR MANUAL (RM840U)
6. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Using a press, install the tapered roller bearing.
(b) Install the counter driven gear with planetary ring gear to
the U/D planetary gear.
(c) Using SST and a press, press in the tapered roller bear-
ing.
SST 09316±60011 (09316±00011)
NOTICE:
Press in the counter driven gear while rotating it.
(d) Using a press, install the parking lock gear.
NOTICE:
Press in the counter driven gear while rotating it.
(e) Using SST and a press, install the differential drive pinion.
NOTICE:
Press in the counter driven gear while rotating it.
SST 09506±35010, 09950±60010 (09951±00250)

D08121
SST
D25609
SST
D25594
SST
D03852
40±96
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(f) Using SST and a press, in the cylindrical roller bearing in-
ner race.
NOTICE:
Press in the counter driven gear while rotating it.
SST 09506±35010, 09950±60010 (09951±00250)
(g) Clamp the U/D planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(h) Using SST, install a new lock nut.
Torque: 280 N
m (2,855 kgf
cm, 207 in.
lbf)
SST 09564±16020
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
(i) Using SST and a torque wrench, measure the turning
torque of U/D planetary gear assy while rotating the
torque wrench at 60 rpm.
SST 09564±16020, 09387±00050
Turning torque at 60 rpm:
0.23 ± 5.01 N
m (2 ± 51 kgf
cm, 2.0 ± 44.3 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(j) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.

4006T±01
D08123
D08124
D08125
D08126
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
40±87
U241E A/T REPAIR MANUAL (RM840U)
UNDERDRIVE CLUTCH ASSY (U241E)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Inspect the U/D clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the U/D clutch pack clearance while applying
and releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57
psi).
Pack clearance: 1.51 ± 1.90 mm (0.0594 ± 0.0748 in.)
If the pack clearance is non±standard, inspect the discs, plates
and flange.
2. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 3 discs and 3 plates from the U/D
clutch drum.

D04077
D03703
SST
D03704
D08127
40±88
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
3. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or even
if a part of the printed mark is defaced, replace all discs.

Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350±32014 (09351±32070)
(b) Using a snap ring expander, remove the snap ring.
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
(c) Remove the clutch balancer and piston return spring from
the U/D clutch drum.
(d) Install the U/D clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.

D08128
D09214
D04078
D08129
D04078
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
40±89
U241E A/T REPAIR MANUAL (RM840U)
(e) Holding the U/D clutch piston with your hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the U/D clutch piston.
5. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6748 in.)
6. REMOVE UNDERDRIVE CLUTCH DRUM O±RING
7. INSPECT UNDERDRIVE CLUTCH DRUM SUB±ASSY
(a) Using a dial indicator, measure the inside diameter of the
U/D clutch drum bushing.
Standard drum bushing:
32.56 ± 32.58 mm (1.2818 ± 1.2826 in.)
Maximum drum bushing: 32.63 mm (1.2846 in.)
If the inside diameter is greater than the maximum, replace the
U/D clutch drum.
8. INSTALL UNDERDRIVE CLUTCH DRUM O±RING
(a) Coat a new O±ring with ATF and install it to the U/D clutch
drum.

D03860
D03704
D03703
SST
D08130
Flange
Disc
Plate 40±90
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the U/D clutch piston with ATF, and install it to the
U/D clutch piston drum.
NOTICE:
Be careful not to damage the O±ring.
(b) Install the piston return spring and clutch balancer to the
U/D clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(c) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09350±32014 (09351±32070)
(d) Using a snap ring expander, install the snap ring to U/D
clutch drum.
NOTICE:

Be sure the end gap of the snap ring is not aligned
with the clutch balancer's claw.

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
groove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
10. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Install the 3 plates, 3 discs and flange.

D08125
D08123
D08124
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
40±91
U241E A/T REPAIR MANUAL (RM840U)
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
11. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the U/D clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the U/D clutch piston stroke while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Park clearance: 1.51 ± 1.90 mm (0.0594 ± 0.0748 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the park clearance is non±standard, select another flange.
HINT:
There are 3 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
A3.0 (0.118)C3.4 (0.134)
B3.2 (0.126)±±

4006S±01
D03796
SST
C83462
D03824
C83463
± AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U241E)
40±85
U241E A/T REPAIR MANUAL (RM840U)
SECOND BRAKE PISTON ASSY (U241E)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
(a) Place SST on the return spring and compress.
SST 09387±00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON
(a) Hold the 2ND brake piston and apply compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi) to the 2ND brake cylinder to re-
move the 2ND brake piston.

C83465
C83465
C83464
C83462
D03796
SST
40±86
± AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
4. REMOVE 2ND BRAKE PISTON O±RING
(a) Remove the 2 O±rings from the 2ND brake piston.
5. INSTALL 2ND BRAKE PISTON O±RING
(a) Coat 2 new O±rings with ATF and install them in the 2ND
brake piston.
6. INSTALL 2ND BRAKE PISTON
(a) Press in the 2ND brake piston into the 2ND brake cylinder
with your hands.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
(a) Install the piston return spring.
(b) Place SST on the piston return spring, and compress the
piston return spring with a press.
SST 09387±00060
(c) Using a screwdriver, install the snap ring.
NOTICE:
Be sure the end gap of the snap ring is not aligned with the
piston return spring claw.